US3947210A - Injection molding apparatus having degating and sprue removal means - Google Patents

Abstract

Apparatus for injection molding parts which comprises forming mold cavities from a set of molds and injecting molding material into the cavities to mold a part on a pin extending up in each cavity; the molded parts are then ejected by being pushed up and off the pins when the molds are moved to expose the parts; ejection involves the application of a substantially uniform force over the base of the moulded part. The apparatus includes means for automatically degating moulded parts from waste material involving initial movement of one of the molds in the set relative to the others; automatic degating can be employed which can occur internally or externally of the molded parts; the molds employed with these specific ejecting and degating means, or with other ejecting and degating means, comprise an upper and lower portion of a universal mold base which forms an integral part of the molding apparatus and to these portions are detachably secured modular mold sections.

Description

BACKGROUND OF THE INVENTION

a. Field of the Invention

This invention relates to improvements in injection molding.

B. Description of Prior Art

Injection molding apparatus presently used has several disadvantages. The ejection of the molded parts from the apparatus can be difficult or awkward when the parting line between the molds defining the mold cavities in which the parts are molded, is horizontal. Usually individual knock-out pins are required, one or more for each molded part, to remove it from the molding apparatus, and this can make the apparatus expensive.

Ejection of the molded parts can also be difficult if the parts to be molded have an uneven base. The knock-out pin or pins may not apply uniform force on the part when stripping it from a core if it acts or they act against an uneven base and damage to the part can occur.

A further disadvantage in injection molding is that the waste or sprue member, which comprises molding material that has set in the channels and passages leading to the mold cavities after molding must be manually separated from the parts molded in the cavities. This is time consuming and expensive. Also, the separation operation may leave a rough surface area on the finished part which may necessitate a further operation to clean or smooth the rough surface area.

A further disadvantage is the face that known injection molding apparatus employs integral molds which have both the mold defining surface and the positioning and moving means on the same member; because of this use of integral molds, it is very difficult and time consuming to change an injection molding machine to mold different parts. Also, the molds required for different parts are expensive since each mold must include both and the mold defining surface and the positioning and moving means.

SUMMARY OF INVENTION

It is the purpose of the present invention to provide improvements in injection molding which overcome or at least minimize the above noted disadvantages.

The present invention provides a novel means for ejecting or stripping molded parts from the molds.

The present invention also provides improvements in the removal of molded parts particularly those having uneven bases from the cores of molding machines. The improvement provides means for the application of a substantially uniform force over the entire base of the part to strip the part from a pin.

The present invention further provides apparatus for automatically degating molded parts, either internally or externally of the parts, when removing them from the mold, the degating apparatus can be used in conjunction with the novel ejecting apparatus.

The invention further provides a molding apparatus which employs molds each made in at least two pieces, with one piece containing the mold-defining surface and the other piece being used to detachably mount the one piece in the apparatus in the proper position. The two piece molds can be employed in molding apparatus which incorporates the novel ejecting means and which incorporates the novel degating means, if desired.

More particularly, the present invention is directed toward molding parts which comprises means forming cavities in a set of molds and means for injecting molding meaterial into the cavities to form a part of each cavity on a pin which extends upwardly in the cavity; the molded parts on the pins are then exposed, and the exposed parts are moved up and off the pins.

The invention is also directed toward the apparatus which comprises a set of molds, at least some of which are movable to form mold cavities in which parts are to be molded; a pin member extends up in each cavity and means direct molding material into each cavity to mold the product which is defined by the open area between the pin member and the mold cavities and means are also provided for pushing the molded part up and off each pin member after the molds are moved to expose the parts on the pin members.

The invention is further directed toward means for molding articles which comprises movable molds together brought to form at least one cavity in which a part is to be molded, in which molding material passes from a sprue in one of the molds, through passages, to the cavity and after the molding material has set, the one mold element is moved an initial distance away from other element to degate or separate waste molding material in the passages and sprue from the part and both the part and the waste material are then removed from the apparatus.

The invention is directed toward an apparatus for use in carrying out a degating method in which the apparatus comprises two movable side molds, and means for moving the molds together to define therebetween open-ended cavities in which parts are to be molded. Two end elements, at least one of which is movable, cooperate with the side elements to substantially close the ends of the cavities. Passage means direct molding material from a sprue in one movable end element to one end of each cavity, pin means on the other end element extend into the cavities. A sprue molding member on the other end element extends into the sprue on the one end element.

The invention is further directed toward molding apparatus having two, movable side elements and means for moving the side elements together to define open-ended cavities in which parts are to be molded. End elements, at least one of which is movable, cooperate with the side molds, to close the cavities. Passage means are provided for directing molding material to one end of each cavity. Means are provided in one of the end elements for separating the molded parts from waste molding material in the passage means when the one end element is moved relative to the side elements after molding.

The invention is still further directed toward molding apparatus which has two, movable side molds, means for moving the side molds together to define cavities in which parts are to be molded and end element, at least one of which is movable, cooperating with the side elements to close the cavities, each element comprises a main base or support member and a die plate detachably connected thereto.

The invention is also directed toward the set of detachable die plates.

BRIEF DESCRIPTION OF DRAWINGS

The invention will now be described in detail having reference to the accompanying drawings in which:

FIG. 1 is a perspective view of a molded article prior to separation of a sprue member from molded parts;

FIG. 2 is a cross-sectional elevational view of the molding apparatus in a closed position;

FIG. 3 is a cross-sectional view of the molding apparatus in FIG. 2 in an open position; after an article has been molded;

FIG. 4 is a fragmentary cross-section of the apparatus taken along line 4--4 of FIG. 2 generally on the mold parting line;

FIG. 5 is an enlarged fragmentary cross-section of the apparatus taken alongline 5--5 of FIG. 4;

FIG. 5A is a cross-section taken alongline 5A--5A of FIG. 5;

FIG. 6 is an enlarged fragmentary cross-section of the apparatus taken alongline 6--6 of FIG. 4;

FIGS. 7A, 7B and 7C are detail views of the apparatus showing different stages of removing the molded parts;

FIG. 8 is a detail of a modification in the part of the apparatus similar to that shown in FIG. 5;

FIG. 9 is a detail of a modification in the part of the apparatus similar to that shown in FIG. 6;

FIGS. 10A, 10B, 10C and 10D are detail views of the modified apparatus of FIG. 9 taken during different stages in removing the molding parts;

FIG. 11 is a cross-section view of another mold embodiment;

FIG. 12 is a fragmentary cross-section view taken alongline 12--12 of FIG. 11; and

FIG. 13 is a front elevation view of a further embodiment of the mold apparatus.

DESCRIPTION OF PREFERRED EMBODIMENTS

The invention is directed toward theinjection molding articles 1 of the type shown in FIG. 1. Thearticle 1 comprises a plurality of identical moldedparts 3 connected to a waste or spruemember 5 by narrow necks orgates 7. Spruemember 5 comprisesrunner members 9 leading fromgates 7 to a main channel member 11 which connects with asprue 13.

Aninjection molding apparatus 15 is provided for moldingarticle 1. Theapparatus 15, as shown in FIGS. 2 and 3, includes a pair ofmovable side molds 17, 19. Theside molds 17, 19 are mounted onstationary wear plates 21, 23 respectively which are in turn, fixed by suitable means, to end orbottom element 25 which acts as a platform. The side molds are located in the side-by-side relation and their facing surfaces formdie cavity surfaces 27, 29 which, when themolds 17, 19 are closed to havesurfaces 27, 29 in proximate relation, provide open-ended cavities 31 in whichparts 3 are molded (as shown more clearly in FIG. 5).

A second end ortop mold element 33 is also provided for cooperating withside elements 17, 19 to close the top end ofcavities 31. Thetop element 33 has a pair of fixedvertical pins 35 which slide intoholes 37 inbottom element 25 to properly locate and guidetop element 33 relative tobottom mold 25.Top element 33 also carries a pair of fixed,inclined pins 39, 41.Pins 39, 41 diverge from one another and slide freely ininclined holes 43, 45 inelements 17, 19 respectively.Top mold elements 33 also includesmembers 47 and top pins 49 (shown in FIG. 4) which extend down tocavities 31 to substantially close their open top ends. Acentral sprue opening 51 is provided intop mold element 33 for receiving the molding material from an external source (not shown). Theopening 51 connects with amain channel 53 formed bygroove 55 in thebottom surface 57 ofmold element 33 and thetop surfaces 59, 61 of the abuttingside mold elements 17, 19 as shown in FIGS. 5 and 5A.Runners 63 lead down frommain channel 53 to eachcavity 31. Eachrunner 63 is formed bygrooves 65, 67 inside mold elements 17, 19 respectively and a portion oftop pin 49.Runner 63 in each case terminates in agate 69 formed by asmall groove 71 leading off fromlarge groove 65.Gate 69 leads intocavity 31.

Bottom mold element 25 carries bottom pins 73, one for eachcavity 31, which extend up into the cavity thus closing the open bottom ends as shown in FIG. 4. The top of the bottom pins 73 abut the bottom ofpins 49 andmembers 47 at the top of the cavityadjacent gate 69. Theparts 3 are molded on bottom pins 73.Bottom mold element 25 also carries sprue member puller means 75. This puller means comprise arod 77, as shown in FIG. 6, extending up from mold bottom 25, through a bore inside mold elements 17, 19 and into opening 51 intop mold element 33. Thetop end 83 ofrod 77 has an undercut 85 for receiving waste material.

Thebottom mold element 25 includes means for ejecting or stripping theparts 3 andsprue member 5 from the mold elements after molding, the stripping means preferably comprises astripper plate 91 mounted on a pair of guide pins 93 onbottom mold element 25. As shown in FIG. 4, the plate has a pair ofholes 95 at its ends for receiving guide and pusher pins 93.

Thestripper plate 91 also hasholes 97, through which bottom pins 73 freely pass, and acentral hole 99, through whichpuller rod 77 freely passes. Pusher pins 93, passing freely throughbottom mold element 25, connectplate 91 to suitable actuating means (not shown).Plate 91 also has asleeve 103 projecting from itstop surface 105 and concentric withhole 99 to surroundpuller rod 77.Mold elements 17, 19, 25 and 33 are all suitably mounted in frame means (not shown) of a molding machine along with the suitable actuating means.

OPERATION

In operation, theelements 17, 19 and 33 are moved to the position of FIG. 2, to formempty cavities 31 as shown in FIGS. 4 and 5. More particularly,top mold element 33 is moved down towardmold 25 bottom by suitable known actuating means (not shown). This downward movement ofmold element 33 causeselements 17, 19 to be brought together viaangled pins 39, 41 (position of FIG. 3 to position of FIG. 2). Whencavities 31 have been formed, suitable molding material is injected into the cavities throughsprue opening 51,channel 53,runners 63 andgates 69. The material is molded about bottom pins 73 in thecavities 31 to form moldedparts 3. After the molding material has set, as shown in FIG. 7A,top mold element 33 is raised by its actuating means away frombottom mold element 25 as shown in FIG. 7B. This upward movement simultaneously causesside elements 17, 19 to move outwardly away from each other viapins 39, 41 causing them to slide out onplates 21, 23; see FIG. 3. This leavesparts 3, onpins 73 exposed as well as attached tosprue member 5. Whentop mold element 33 is raised, thesprue member 5, consisting of waste molding material in opening 51,channel 53,runners 63 andgates 69, remains in place, held by the undercut 85 on the sprue member puller means 75.Stripper plate 91 is now actuated to move up frombottom mold element 25 as shown in FIG. 7C. Asplate 91 moves vertically up,sleeve 103 pushessprue member 5 offrod 77 whiletop surface 105 of the plate is simultaneously pushingparts 3 off bottom pins 73.Article 1 consisting of joinedparts 3 andsprue member 5, falls away, after clearingrod 77, and pins 73 and the apparatus is ready for the next molding operation.pars 3 can later be manually separated fromsprue member 5.

Preferably, thetop surface 105 ofplate 91 is contoured as shown at 107 to conform to the contoured bottom surfaces 109 of theparts 3 being molded. Theside elements 17, 19 are shaped to receive this contoured surface where they abut over it. The contouredtop surface 105permits parts 3 with unevenbottom contours 109 to be pushed offpins 73 with uniformly applied vertical pressure. Theparts 3 are not subjected to twisting forces which could damage them during stripping.

Whileparts 3 can be ejected from the apparatus integrally withmember 5, it is preferred to separate or degate theparts 3 frommember 5 automatically prior to stripping. To provide automatic degating, eachtop core pin 49 is provided with a transverse notch 111 extending offrunner 63 andadjacent gate 69 as shown in FIG. 8. Also, puller means 75 is mounted inbottom mold 25 to have limited vertical movement rather than being fixed as before. To this end as shown in FIG. 9,rod 77 passes freely through a bore 113 inbottom mold element 25.Rod 77 has anenlarged head 115 which fits in acounterbore 117 inbottom mold element 25.Head 115 has a length shorter than the length ofcounterbore 117, FIG. 9-10D which is closed with aplug 119. This permitshead 115 to freely move incounterbore 117.

AUTOMATIC DEGATING OPERATION

In operation, molding material enters notches 111 during molding ofparts 3 and sets as shown in FIG. 10A. As thetop mold element 33 starts moving upwardly its engagement with the waste material in the notch will cause the material to break away fromparts 3 atgates 69 and as shown in FIG. 10B. Thesprue member 5 can be raised a short distance because the puller means 75 about which it is mounted, has limited vertical movement in counterbore. Asmember 5 breaks away fromparts 3,head 115 ofrod 77 encounters thebase 121 ofcounterbore 117 and is prevented from rising further. The travel ofhead 115 ofrod 77 incounterbore 117permits plates 27 and 29 to separate a distance greater than the depth of notch 111 in thepins 49. This makes possible the release of the material that has been molded into this notch 111 and the retention ofmember 5 onrod 77. The undercut 85 holds ontosprue member 5 as it is separated from thetop mold element 33 and pins 49, as shown in FIG. 10C.Member 5 is then stripped offrod 77 as before through upward movement ofplate 91; see FIG. 10D, and now falls away separate from stripped offparts 3.

The automatic degating operation described has separatedsprue member 5 fromparts 3 at an external location onparts 3. The separation occurs atgates 69. While external degating cannot always be avoided, depending on the part to be made, it does tend to leave a rough surface on the part which may require smoothing. Therefrom, in another embodiment of the invention, the molds are modified to provide automatic degating of the parts internally thereof. In this embodiment, the top core pins are extended into the parts being molded. As shown in FIGS. 11 and 12, fourmold elements 17A, 19A, 25A and 33A are employed in a similar manner aselements 17, 19, 25 and 33, to formmold cavities 31A. When the molds are in the molding position, core pins 49A extend down fromtop mold element 33A intocavities 31A. The core pins 49A abut with bottom core pins 73A extending up from bottom mold 25A at a plane A--A slightly below thetop end 201 ofcavity 31A; see FIG. 11. Achannel 203 is formed bygroove 205 intop mold element 33A cooperating withtop surface 207, ofside mold element 17A.Channel 203 directs molding material from asprue opening 51A intop mold element 33A tohorizontal runners 213 formed bygrooves 215 intop mold element 33A andtop surface 207 ofside mold element 17A.Horizontal runners 213 communicate withvertical runners 217 extending down to a point just abovecavities 31A.Runners 217 are each formed by agroove 219 incore pin 49A and side wall of a bore defined byside elements 17A, 19A for receivingpin 49A. A narrowblind groove 221 extends from the end ofgroove 219 inpin 49A to a point just withincavity 31A. The molding material flows throughgroove 221 into thecavity 31A to mold the material. Thegroove 221 acts as a gate. Upon completion of the molding, after the material has set,top mold element 33A is initially raised a short distance to separatesprue member 5A fromparts 3A. Separation occurs due to pin 49A shearing off the material ingroove 221 from the material ofpart 3A. It is noted that the shearing, and thus separation occurs internally ofpart 3A, and this is a clean separation.

After internal degating,top mold element 33A continues to move away withsprue member 5A being pulled away therefrom by sprue member puller means 75A as before. The travel ofhead 115 ofrod 77 incounterbore 117permits plates 27 and 29 to separate a distance greater than the depth ofnotch 219 in thepins 49. This makes possible the release of the material that has been molded into thisnotch 219 and the retention ofmember 5A onrod 77. Thesprue member 5A andparts 3A are then stripped off the rod 77A and bottom core pins 73A as before by stripper means such as a stripper plate 91A. Stripper plate 91A can include a contoured top surface, as before, to strip offparts 3A having contoured bottom surfaces.

In all the embodiments described thus far, the molds used incorporate the die surfaces and pins integrally with the means on the molds to locate and to be used in moving the molds. The present invention contemplates employing molds, each made in at least two pieces, with one piece forming a base member having the locating and moving means thereon and the other piece having a die surface. The piece with the die surface can be detachably connected to its base member. The base members of the molds remain attached to the frame of the molding apparatus. The pieces or plates carrying the die surfaces however can be readily replaced by a different set of die plates for molding a different part. The molding apparatus incorporating the die plates, can be used with, or without, the ejecting means and degating means previously described.

As shown in FIG. 13, theapparatus 301 incorporating separate die plates comprisesside mold elements 303, 305,top mold element 307 andbottom mold element 309.Bottom mold element 309 comprises a base orplatform member 311 fixed to the frame (not shown) of the molding machine. Detachably connected tobase member 311 by suitable means, such as bolts (not shown) isbottom die plate 315 having pins 317 extending up therefrom. A stripper plate 319 forms part ofdie plate 315 and can be moved by suitable means such aspush rods 320 relative to pins 317 to strip the parts being molded off the pins. Dieplate 315 can also mount puller means 321 for the sprue member.

Theside mold elements 303, 305 each comprise a base orcam member 323 mounted for sliding movement on aplate 325 fixed onplatform 311.Cam member 323 have aninclined bore 327 for receiving aninclined pin 329 extending down fromtop mold 307. Mounted on thesurface 331 of thecam members 323 which face each other is adie plate 333. Dieplate 333 is detachably connected tocam member 323 bybolts 335. Dieplate 333 has a die surface which, when the twoplates 333 are abutting, form mold cavities for molding parts.

Top mold element 307 comprises atop member 339 connected to suitable actuating means (not shown) in the apparatus and mounted for movement away or towardplatform 311 by vertical guide pins 341.Top member 339 also carriesinclined pins 329 which, whentop member 339 is raised or lowered, movescam members 323 away or toward one another. Detachably connection totop member 339 bybolts 343 is atop die plate 345 having top pins and means for directing molding material from injection means (not shown) to the cavities formed by the die plates in the molding position. As described, the plates forming the mold cavities can be readily replaced when it is desired to mold a new part without having to replace the die plate positioning and moving means.

Claims (6)

I claim:

1. In an injection molding apparatus including two juxtapositionable side molds including cooperating means for forming a sprue and gates communicating with open-ended article-forming cavities;

juxtapositionable bottom and top mold elements, at least one of said top and bottom mold elements being displaceable vertically relative to the other and including means for closing the open-ended article-forming cavities;

means operatively connecting said side molds and bottom and top mold elements for moving them simultaneously and in unison and causing the side molds to be spaced laterally at a vertical parting line therebetween when the top mold element is raised vertically from said bottom mold element, the improvement comprising:

automatic article degating means and sprue-removingmeans including bottom pins on said bottom mold element projecting into the article-forming cavities at the parting line for conforming to a surface of the articles being molded and supporting the molded articles thereon when the side molds are moved apart at the vertical parting line; sorue-removing means

sprue-pulling means of said bottom mold element comprising a sprue-holding rod projecting from the bottom mold element at the vertical parting line and including an upper portion projecting into the sprue, said sprue-holding rod including means for receiving on the portion projecting into the sprue molding material therein so that the sprue of the articles and the molded articles are integrally connected by the gate;

top pins and top members depending from said top molded element at the vertical parting line into said article-forming cavities for movement with the top mold element relative to the bottom mold element and side molds upon upward relative movement of said top mold element; and

stripper means on said bottom mold element and including means for moving the stripper means relative to the bottom pins and sprue-holding rod when the side molds are apart at the vertical parting line when the sprue and the molded articles are exposed between the side molds; said top pins comprising automatic degating means including means for receiving mold material therein for automatic degating of the molded articles from the sprue prior to the sprue being separated from the sprue-holding rod, said sprue-holding rod being displaceably mounted in said bottom mold element and having limited relative movement with respect to said bottom mold element, said top pins and sprue-holding rod having means affording a timing sequence between article-degating and sprue-removal whereby initial upward movement of said top mold element degates the articles from the sprue retained on the sprue-holding rod, and the stripper means subsequently strips the sprue from the sprue-holding rod after the side molds are spaced at the vertical parting line.

2. The structure as claimed in claim 1, in which said stripper means includes a plate having an upper surface portion with a contour for corresponding to the bottom contour of each exposed molded part for applying a substantially uniform force on each exposed molded part when stripping it off the bottom pins.

3. The structure as claimed in claim 1, wherein said side molds, top and bottom mold elements comprise side, top and bottom base members, and side, top and bottom die plates detachably connected to the respective base members.

4. The structure as claimed in claim 1, in which said stripper means comprises a displaceable stripper plate having portions through which said bottom pins and sprue-holding rod freely project for permitting relative movement between said stripper plate and the bottom pin and the sprue-holding rod.

5. The structure as claimed in claim 4, in which said stripper plate includes a sleeve element circumposed about said sprue-holding rod and displaceable with said plate for dislodging the sprue and material molded about said sprue-holding rod.

6. The structure as claimed in claim 1 in which said top pins extend from the top mold element into said article-forming cavities, said top pins abutting said bottom pins in a plane below an upper portion of the article-forming cavity, said top pins including a gate-forming groove extending to a point within the article-forming cavities whereby upward movement of said top mold element relative to said bottom mold element and the sprue-holding rod causes internal degating of the molded article within the article-forming cavity.

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